Volvo 1.6D V50/C30/S40 Diesel Service Guide [Oil & Filters] 2011-2016 D2 Drive | Ford Peugeot Mazda 

Volvo 1.6D V50/C30/S40 Diesel Service Guide [Oil & Filters] 2011-2016 D2 Drive | Ford Peugeot Mazda
In this video I complete the annual service on my Volvo V50, consisting of an engine oil change, oil filter change, air filter change and the addition of a cabin filter change. Topped off by a service warning reset.
Here is everything you need to follow this guide:
Castrol Magnatec 5W30 A5 Oil: ebay.us/MHmToT (I got 5L as it was no dearer than 4L)
Bosch Oil Filter: ebay.us/vXOWOS
Air Filter: ebay.us/K0phZJ
Cabin Filter (Pollen Filter): ebay.us/wmF6fn
This guide applies not only to the Volvo V50 1.6D, but also the C30, S40 and various other 1.6 diesel vehicles which share this engine, such as Fords, Citroens and Peugeots.
The 2011 Volvo V50 1.6D Drive I'm working on has the 2011-2016 D2 engine, code D4162T and proving to be a high mile hero engine with over 160k miles on the clock and still delivering 60mpg+ when driven carefully.
Starting with the oil change, I'd let the car warm up by driving it to the garage, that always helps. I raised the front of the car onto wheel stands and removed the undertray.
The undertray on a Volvo is usually held on the Torx screws, I think T20 or T25.
With that out of the way, I removed the sump plug which is a 21mm hex head screw and allowed the oil to drain into a pan of sufficient capacity (at least 4L). I also removed the top oil cap to prevent any vacuum.
I turned my attention to the oil filter. It's quite well hidden on these engines. The oil filter housing is buried beneath the air filter housing, hidden by coolant pipework. The trick is to partially remove the air filter housing and put it to one side so you can access it as shown in the video.
Now you can see the cap of the oil filter housing, this has a 27mm hex head on it for removal. Once you have the cap moving, it's advisable to get a bin bag ready to catch the filter and the oil that will follow. Otherwise your engine bay will become a disaster zone.
With the oil filter removed, install the new oil filter and the new o-ring, ensuing the oil filter o-ring is seated properly to avoid future leaks.
Putting the oil filter in is a little more tricky, there is a locating dowel on the filter, you can clip the filter into the housing cap and aim it correctly at the hole in the bottom of the filter housing, or you can out the filter into the housing and screw the cap on top. Both methods should be done carefully to avoid crunching the new filter.
The oil filter housing cap torques up to 25nm when you put it back.
With the air filter housing still loose, its a good chance to more easily switch the air filter which is drum-shaped. The end of the large filter actually makes up one side of the air box. It's easy to swap once you have the air filter housing lid removed by slackening the 4 7mm captive hex screws. Once this is done, re-seat your air filter into its home and make sure the MAF is plugged back in and any lines back in their holders.
Following this, replace the sump plug. Its recommended to use a fresh copper washer to help this seal. Sadly I didn't have one the correct size, and they don't seem to come with the Bosch oil filter. So as an alternative I annealed the old washer, softening it fresh to seal again.
The sump plug torques up to 30nm, don't overtighten this as you risk stripping the threads.
Pour in your Castrol 5W-30 oil, this engine takes 3.8L, pour about that much in, run the car for a short while, then check again and top up as necessary. I always run mine toward the max marker on the dipstick for peace of mind.
The cabin filter on a RHD V50 is located in the passenger footwell, drop the fuse box and pull it out of the way, fold the carped down, and it will reveal the most ridiculously positioned filter you've ever seen. Unscrew the white plastic wingnut and remove the plastic cover. Drag the old filter out which is a challenge in itself and likely requires a vacuum to clean up the mess you'll make.
To replace, squeeze the new pollen filter down and slide it in, allow it to retake its original square shape before replacing the cabin filter cover.
To reset the service indicator, turn your key to position 1, press and hold the trip reset and turn it to position 2. Release when the i flashes. Your Volvo service is complete.
The engine is actually a Ford unit and is used by a lot of different manufacturers in the cars listed below, so this guide applies not just to Volvo D2:
Citroen 1.6 HDi
Peugeot 1.6 HDi
Ford 1.6 TDCi
Volvo D2
Mazda 1.6D
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